'99 C2 Cab Convertible Top Timeout. Help!

[dabigfish]

I've searched through the forum but can't find a topic with my flavor of problem. I have a 99 996 C2 Cab. Replaced the convertible top cover. Drove for a while and operated normally. Finally got around to reinstalling the top liner. Opened and closed once each with no problems. Went to open it one day and the sequence timed out on what I believe to be the last step in the sequence which is the latching down of the clamshell. My suspicion is that there is some microswitch for the clamshell down indicator that is not sending to tell the latch to actuate. Since this was shortly after reinstalling the top liner, I thought that this may be because the lining was bunching up in some area or another causing pressure on the clamshell when it was trying to lower. The trouble is that I get the same timeout error on the closing (top up) sequence when there is nothing under the clamshell. Here's what I've tried so far:

-Take the liner back out

-Clear faults & calibrate top with Durametric

-Have second person apply pressure down on the clamshell while closing

-Disconnect tension cables on rear bow

-"tapped" all relays in the box

-Open and shut engine bay cover

For now, I'm driving with the hard top on. The convertible top in operation light is persistent on the dash and I get the annoying "you've left something unlocked" horn beep when I arm the alarm. And most of all, I'm missing the use of my cab in the great weather. This problem is killing me. Help please!

[wvicary]

If you see nothing caught anywhere then I would open the top slightly and measure that the clamshell is opening the same amount side to side by measuring from the edge of the shell to a fixed point on the body. I've had the gear mechanism strip out a few teeth and throw out the timing of events. The gear drive for your top has been updated to a new part number.

[wooz797]

if you remove the cover behind the rear seats (carpet wall) you should be able to see the moter/transmission for the cover. There is an allen key provided there its red handled and you can open the cover manually, I think its counterclockwise (and its in the owners manual). once the cover is openedpush it back down manually and tighten the allen-3 turns (left handed thread) or the opposite way used to open the cover. then try to operate roof normally.

[dabigfish]

If you see nothing caught anywhere then I would open the top slightly and measure that the clamshell is opening the same amount side to side by measuring from the edge of the shell to a fixed point on the body. I've had the gear mechanism strip out a few teeth and throw out the timing of events. The gear drive for your top has been updated to a new part number.

Nothing visibly caught near any of the operating parts. The clamshell is level within reason (I didn't use a micrometer). Thanks for the suggestion though.

[dabigfish]

if you remove the cover behind the rear seats (carpet wall) you should be able to see the moter/transmission for the cover. There is an allen key provided there its red handled and you can open the cover manually, I think its counterclockwise (and its in the owners manual). once the cover is openedpush it back down manually and tighten the allen-3 turns (left handed thread) or the opposite way used to open the cover. then try to operate roof normally.

I looked at the manual operator but I was hesitant to try that for fear or screwing things up more. There are a bunch of warnings in the owner's manual about "emergency" operation. I'll give that a try the next time I have the hardtop off.

Question: If it's 3 turns after pushing it back down should I also expect 3 turns to open the clamshell? I'm guessing that I should keep track so I can put back what I took out, so to speak.